New Holland TD95 Tractor Service Repair Manual Instant Download

1
TD60 TD70 TD80 TD90 TD95 STRADDLE MOUNT
MODEL TRACTORS SERVICE MANUAL
SECTIONS GENERAL . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 00 ENGINE . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10 CLUTCH . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 18 GEARBOX . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 21
TRANSMISSION OF MOTION . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
23 FRONT MECHANICAL TRANSMISSION . . . . . . . .
. . . . . . . . . . . . . . . . . . 25 REAR
MECHANICAL TRANSMISSION . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 27 POWER TAKEOFF
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 31 BRAKES
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 33 HYDRAULIC SYSTEMS . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 35 STEERING . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 41 AXLE AND
WHEELS . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
44 ELECTRICAL SYSTEM . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 CAB . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 90
S
E
R
V
I
C
E
2

• INTRODUCTION
• This manual is divided into sections identified
  by twofigure numbers. Each section has
  independent page numbering.
• For ease of reference, these sections have the
  same numbers and names as the Repairs Rate Book
  sections.
• The different sections can easily be found by
  consulting the table of contents on the following
  pages.
• The document number of the manual and the
  edition/update dates are given at the bottom of
  each page.
• Pages updated in the future will be identified by
  the same document number followed by a twofigure
  update number (for example 1st update
  603.54.331.01 2nd update 603.54.331.02 etc.)
  and the corresponding is- sue date.
• These pages will be supplemented by a reprint of
  the updated contents page.
• The information contained in this manual was
  current on the date printed on each section. As
  NEW HOLLAND constantly improves its product
  range, some information may be out of date
  subsequent to modifications im- plemented for
  technical or commercial reasons or to meet legal
  requirements in different countries.
• In the event of conflicting information, consult
  the NEW HOLLAND Sales and Service Departments.
• IMPORTANT WARNINGS
• All maintenance and repair work described in this
  manual must be performed exclusively by NEW
  HOLLAND service technicians in strict accordance
  with the instructions given and using any
  specific tools necessary.

TEXT AND ILLUSTRATIONS ARE THE PROPERTY OF NEW
HOLLAND ??????????????? No part of the text or
illustrations may be reproduced PRINTED IN
????? NEW HOLLAND ????????. ???????????????????
??????????????? SERVICE Technical Publications
Special Tools Print no. ???.??.???.?? 06
2002
3
NEW HOLLAND
Repair ManualTD Straddle Mount Series
Tractors CONTENTS
GENERAL
SECTION 00
General Instructions and Health and Safety
Chapter 1
Section
Description Page General instructions . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 1 Notes for spare parts . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 Notes for equipment . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety rules . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 3 Consumables . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
6
00 000
ENGINE
SECTION 10
Engine System
Chapter 1
Section
Description Page General specifications . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 2 Data . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 5 Torque settings . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 24 Tools . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 25 Crosssectional views . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 28 Lubrication and cooling system diagrams .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 32 Troubleshooting .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 35 Removal Installation
Overhaul . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 39 Checks, dimensions and repairs . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 80
10 000
10 001
CLUTCH
SECTION 18
Clutches Chapter 1 Description Page
Section
18 000
General Characteristics . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
1 Tightening Torques . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
2 Tools . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 3 Sectional views . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
36 Clutch Troubleshooting . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
7 Removal Refitting . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 815 Overhaul
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 1619
18 110 10 18 110 30
4
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5
Checks, measurements and repairs . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 2021 18 100 40 Adjustments . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 2223 GEARBOX SECTION 21
Mechanical Transmission (12x4) Chapter
1 Description Page Main data . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 1 Tightening torques . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 2 Tools . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 3 Section views . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 5 Description and
operation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 8 Fault diagnosis . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 8 Removal Refitting . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . see
sect 27
Section
21 000
21 110
Reverser (12x12) Chapter 2 Description Page Main
data . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1 Tightening torques . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
2 Tools . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 3 Section views . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 3 Description and operation . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
5 Fault diagnosis . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
5 RemovalRefitting . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 6
Section
21 000
21 110
Reverser and Creeper (20x12) Chapter
3 Description Page Main data . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 1 Tightening torques . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 2 Tools . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 3 Section views . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 4 Description and
operation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 6 Fault diagnosis . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 6 RemovalRefitting . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 7
Section
21 000
21 110
DRIVE LINES SECTION 23
Drive Lines Chapter 1 Description Page
Section
23 000
Main specification . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1 Torque settings and Tools . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
2 CrossSectional views . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
3 Transmission shafts and guard (Disassembly
Assembly) . . . . . . . . . . . . . . . . . . . .
. . . . . . . 4 Drive gear housing (Removal
Installation) . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 56 Drive
gear housing removed (Disassembly Assembly) . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 7
23 101 26 23 101 40 23 101 42
6
FRONT AXLE MECHANICAL TRANSMISSION
SECTION 25
Chapter 1
Front Axle Mechanical Transmission Description
Section
Page
25 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crosssectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
25 100 30 Complete front axle. Removal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 38 Front axle. Removal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25 108 4647 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 102 24 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
25 100 27 Front axle differential with LIMSLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
44 511 80 Leading drive wheels toein check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR AXLE AND TRANSMISSION
SECTION 27
Chapter 1
Rear Axle And Transmission Description
Section
Page
27 000
Main specification . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1 Torque settings . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
3 Special tools . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 5 Sectional views . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
6 Description and operation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 7 Fault
finding . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
8 RemovalRefittingOverhaul . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 9
27 100
POWER TAKEOFF SECTION 31
Mechanical Power Take Off Chapter
1 Description Page Main specifications . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 1 Tools . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 3 Torque settings . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 4 Sectional drawings . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 5 Description and operation . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 8 Troubleshooting . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 9 Removal Refitting . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10 Bench overhaul . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 13
Section
31 000
31 101
7
BRAKING SYSTEM
SECTION 33
Braking System Chapter 1 Description Page
Section
31 000
Main specifications . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
1 Tools . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 2 Torque settings . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 3 Sectional drawings . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 5 Description and operation . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
6 Troubleshooting . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
7 Removal Refitting . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
7 Bench overhaul . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 12
31 101
HYDRAULIC SYSTEM SECTION 35
Rear Mechanical Hydraulic Lift Chapter
1 Description Page Main specification . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 1 Torque settings . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 5 Tools . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 6 Sectional views . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 7 Description and operation
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 9 Fault diagnosis . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 Removal Refitting Overhaul . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 15
Section
35 000
35 114
Open Centre System Auxiliary Control
Valves Description
Chapter 2 Page
Section
35 000
Main data Tools . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
1 Sectional views . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
2 Description and operation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 3 Fault
diagnosis . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . see lift in chapter 1 Overhaul . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 6
35 204
Trailer Brake Auxiliary Control Valve Chapter
3 Description Page Section views . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 1 Description and operation . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 1 Trailer brake remote control valve
linkage adjustment . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 6
Section
35 000
STEERING SECTION 41
Steering Chapter 1 Description
Section
Page
41 000
Principal data . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
1
Torque settings . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
7 Fault diagnosis . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
9 Tools . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 10 Hydrostatic steering control valve
RemovalRefitting . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 11 Hydrostatic steering
control valve DisassemblyAssembly . . . . . .
. . . . . . . . . . . . . . . . . . 14
41 204
8
Hydrostatic steering control valve Bench
testing . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 28 Hydrostatic steering
oil pump DisassemblyAssembly . . . . . . . . .
. . . . . . . . . . . . . . . . . . 30 Steering
cylinder RemovalRefitting . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 32
41 206 41 216
FRONT AXLE AND WHEELS SECTION 44
Front Axle And Wheels Chapter 1 Description Page
Principal data . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
1 Sectional views . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
3 Torque settings . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
4 Equipment Fault diagnosis . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
5 RemovalRefittingOverhaul . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 6 Wheel hub
disassemblyassembly . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 9 Stub axle overhaul . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 12
Section
44 000
44 101 44 101 44 101
ELECTRICAL SYSTEM SECTION 55 Instruments Chapter
1 Section Description . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . Page
55 418
Analogue instruments . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
1 Introduction . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 1 Maintenance . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
14 Components Chapter 2 Description . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Page
Section
55 500
Introduction . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
1 Component description . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 2
Starting System Chapter 3 Description . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Page
Section
55 000
Technical information . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
1 Tightening torques . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1 Description and operation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
2 Troubleshooting . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
4 System tests . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
5 Removal and reinstallation of starter motor .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 7 Servicing . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 8 Bench tests .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 10 Charging
System Chapter 4 Description . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . Page
55 201
Section
55 000
Technical information . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
1 Tightening torques . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1 Description and operation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 2 System
testing and troubleshooting . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 4 Removal, reinstallation
and servicing . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
10 Battery Chapter 5
55 301
9
Section
Description . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . Page
55 000
Technical information . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
1 Description and operation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 1 Removal
and reinstallation . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 2 Battery checking
and maintenance . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 3 Charging the battery . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 Battery problems Frequent causes . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 7 Electrical
Circuits Chapter 6 Description . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . Page
55 301
Section
55 100
Fuses (all versions) . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
2 Symbols used in electrical circuits . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 3 Electrical
wire colour coding . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 4 Electrical
diagrams Generall diagrams . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 5 Startup circuit . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 6 Side lights, main and dipped headlights,
parking light circuit . . . . . . . . . . . . . .
. . . . . . . . . . . . 7 Direction indicator and
hazard warning light circuit . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 8
Work lamp circuit . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
9 Windscreen and rear window wiper/washer circuit
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 10 Heating and airconditioning
system circuit . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
11 Analogue instrument circuit . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 12
BODYWORK AND DRIVER POSITION SECTION 90 Bodywork
And Driver Position Chapter 1 Section Description
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . Page 90
000 DisassemblyAssembly . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 1
10
1
SECTION 00 GENERAL CHAPTER 1

• GENERAL INSTRUCTIONS
• IMPORTANT NOTICE
• All maintenance and repair operations described
  in this manual should be carried out exclusively
  by the FIATA- GRI authorised workshops. All
  instructions detailed should be carefully
  observed and special equipment indi- cated
  should be used if necessary.
• Everyone who carries out service operations
  described without carefully observing these
  prescriptions will be
• directly responsible of deriving damages.
• SHIMMING
• At each adjustment, select adjusting shims,
  measure them individually using a micrometer and
  then sum up recorded values. Do not rely on
  measuring the whole shimming set, which may be
  incorrect, or on rated value indicated for each
  shim.
• ROTATING SHAFT SEALS
• To correctly install rotating shaft seals,
  observe the following instructions
• Let the seal soak into the same oil as it will
  seal for at least half an hour before mounting
• Thoroughly clean the shaft and ensure that the
  shaft working surface is not damaged
• Place the sealing lip towards the fluid. In case
  of a hydrodynamic lip, consider the shaft
  rotation direction and orient grooves in order
  that they deviate the fluid towards the inner
  side of the seal
• Coat the sealing lip with a thin layer of
  lubricant (oil rather than grease) and fill with
  grease the gap between the sealing lip and the
  dust lip of double lip seals

11
SECTION 10 ENGINE CHAPTER 1
1
SECTION 10 ENGINE
Chapter 1 Engine
CONTENTS
Section
Description Page General specification . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 Data . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 5 Tightening torques . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 24 Tools . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 25 Crosssectional views . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
28 Lubrication and cooling system diagrams . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 32 Fault diagnosis . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 35 Removal Installation
Overhaul . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 39 Checks, dimensions and repairs . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 80
10 000
10 001
603.54.471.00 03 2004
12
2
SECTION 10 ENGINE CHAPTER 1
GENERAL SPECIFICATION 3cylinder 4cylinder
Engine type TD 60 model normally aspirated type 8035.05D.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model turbocharged type 8035.25C.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model normally aspirated type 8045.05R.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model turbocharged type 8045.25.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model turbocharged type 8045.25L.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston diameter TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total displacement TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum power 2000/25 EC at 2500 rpm TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum power ECE R 24 at 2500 rpm TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 60 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 70 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 80 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 90 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 95 model . . . . . . . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type TD 60 model normally aspirated type 8035.05D.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model turbocharged type 8035.25C.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model normally aspirated type 8045.05R.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model turbocharged type 8045.25.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model turbocharged type 8045.25L.639/939 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston diameter TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total displacement TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum power 2000/25 EC at 2500 rpm TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum power ECE R 24 at 2500 rpm TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 60 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 70 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 80 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 90 model . . . . . . . . . Maximum torque (daNm) at 1500 rpm TD 95 model . . . . . . . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, 4stroke Direct 3 4 dry forcefitted in dry forcefitted in cylinder block cylinder block 104 mm 104 mm 104 mm 104 mm 104 mm 115 mm 2931 cm3 2931 cm3 3908 cm3 3908 cm3 3908 cm3 17 to 1 normally aspirated 16.5 to 1 turbocharged 43.4 kW (59 HP) 50.7 kW (69 HP) 58.8 kW (80 HP) 65.5 kW (89 HP) 69.1 kW (94 HP) 41.2 kW (56 HP) 47.8 kW (65 HP) 55.9 kW (76 HP) 63.3 kW (86 HP) 66.9 kW (91 HP) 2500 rev/min 20.7 25.0 27.9 32.0 33.7 4 5 Structural, cast iron Diesel, 4stroke Direct 3 4 dry forcefitted in dry forcefitted in cylinder block cylinder block 104 mm 104 mm 104 mm 104 mm 104 mm 115 mm 2931 cm3 2931 cm3 3908 cm3 3908 cm3 3908 cm3 17 to 1 normally aspirated 16.5 to 1 turbocharged 43.4 kW (59 HP) 50.7 kW (69 HP) 58.8 kW (80 HP) 65.5 kW (89 HP) 69.1 kW (94 HP) 41.2 kW (56 HP) 47.8 kW (65 HP) 55.9 kW (76 HP) 63.3 kW (86 HP) 66.9 kW (91 HP) 2500 rev/min 20.7 25.0 27.9 32.0 33.7 4 5 Structural, cast iron
603.54.471.00 03 2004
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SECTION 10 ENGINE CHAPTER 1
3
(continued)
GENERAL SPECIFICATION 3cylinder 4cylinder
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal oil pressure, with engine hot and at fast idling speed . Lube pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For further lubrication data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with gear pump camshaft 21 mesh filter on oil intake and cartridge filter on delivery line 2.9 to 3.9 bar (3 to 4 kg/cm2) built into pump housing 3.5 bar (3.6 kg/cm2) See page 23 forced, with gear pump camshaft 21 mesh filter on oil intake and cartridge filter on delivery line 2.9 to 3.9 bar (3 to 4 kg/cm2) built into pump housing 3.5 bar (3.6 kg/cm2) See page 23
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator on TD60, TD70, TD80 and TD90 models . . . . . . . . . . Radiator on TD95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . . Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . middle green section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation 3row vertical pipes with copper fins fourrow vertical pipes with copper fins 4blade steel exhauster fan 6blade steel exhauster fan (TD95) centrifugal vanetype 11,403 Thermostat coloured scale divided into 3 sections from 30? to 65? C from 65? to 105? C from 105? to 115? C See page 23 coolant circulation 3row vertical pipes with copper fins fourrow vertical pipes with copper fins 4blade steel exhauster fan 6blade steel exhauster fan (TD95) centrifugal vanetype 11,403 Thermostat coloured scale divided into 3 sections from 30? to 65? C from 65? to 105? C from 105? to 115? C See page 23
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rev counter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . . incorporated in control panel from gear on camshaft 1800 rev/min incorporated in control panel from gear on camshaft 1800 rev/min
(continued)
603.54.471.00 03 2004
14
4
SECTION 10 ENGINE CHAPTER 1
(continued)
GENERAL SPECIFICATIONS 3cylinder 4cylinder
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
Intake overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
start before T.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
end after B.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
Exhaust overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
start before B.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
end after T.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
Valve clearance for normal running (engine cold) overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20 overhead valves operated by a camshaft located in the engine block through tap- pets, pushrods and rockers. Camshaft is driven by the crankshaft through helical gears. 12? 31? 50? 16? 0.45 mm 0.30 t 0.05 mm 0.30 t 0.05 mm See page 20
Fuel System dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Minimum fuel flow rate with pump shaft rotating dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
at 1600 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Operated by eccentric cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Allspeed governor, incorporated in pump BOSCH dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
Automatic advance regulator, incorporated in pump BOSCH dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
For further fuel system data dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
For fixed advance (pump setting for start of delivery before dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15 dual cartridge dry air filter with clogged filter indicator, centrifugal prefilter and automatic dust ejector double diaphragm mesh filter in fuel supply pump and replaceable cartridge on delivery line to injection pump. 100 litres/hour on camshaft distributor type centrifugal counterweights hydraulic see pages 5 to 15 refer to the data for the relevant engine type in the table on pages 5 to 15
TDC) Pressure setting Injection order, and other informa